Safe Work Procedure: Welding

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the necessary safety precautions and procedures to be followed when performing welding operations. It applies to all workers involved in welding activities, including but not limited to arc welding, gas welding, and cutting operations [1]. This procedure aims to minimize the risks associated with welding, such as burns, eye injuries, fire hazards, exposure to harmful fumes, and electric shock 4, 5.

This SWP is applicable in various work environments, including construction sites, maintenance shops, and confined spaces 2, 5. It covers both indoor and outdoor welding activities. This procedure does not cover submerged arc welding 3, 13.

Related documents that should be consulted in conjunction with this SWP include the manufacturer's instructions for welding equipment, relevant safety data sheets (SDS) for welding materials, and the site-specific emergency response plan [2].

2. Definitions

Arc Welding: A welding process that uses an electric arc to create heat to melt and join metals 1, 3.

Gas Welding: A welding process that uses a fuel gas and oxygen to create heat to melt and join metals 1, 3.

Confined Space: A relatively small or restricted space such as a tank, boiler, pressure vessel, or small compartment of a ship 2, 9.

Hot Work: Any work that involves burning, welding, cutting, brazing, grinding, or similar fire-producing operations [3].

3. Responsibilities

3.1 Supervisors

• Ensure that all workers are properly trained and competent to perform welding tasks 6, 14.
• Provide workers with the necessary personal protective equipment (PPE) and ensure its proper use 4, 17.
• Conduct pre-job briefings to discuss potential hazards and control measures 5, 12.
• Ensure that the work area is safe and free of fire hazards 5, 17.
• Secure authorization for cutting or welding operations from the designated management representative [3].

3.2 Workers

• Follow all safety procedures and instructions outlined in this SWP 14, 17.
• Use the appropriate PPE as required 4, 17.
• Inspect equipment and tools before use and report any defects [4].
• Report any hazards or incidents to the supervisor immediately [5].
• Participate in pre-job briefings and ask questions if unsure about any aspect of the task [3].

3.3 Health and Safety Representative

• Assist in the development and review of this SWP [1].
• Conduct regular inspections of welding operations to ensure compliance with safety procedures 5, 12.
• Investigate incidents and recommend corrective actions [5].

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Burns	Skin burns from sparks, hot metal, or UV radiation	Wear appropriate PPE, such as flame-resistant clothing, gloves, and aprons 4, 9. Use screens or shields to protect others from sparks and radiation 4, 17.
Eye Injuries	Arc flash, flying debris, or chemical splashes	Wear appropriate eye protection, such as welding helmets with filter lenses, safety glasses, or face shields 3, 13. Ensure helpers or attendants are provided with proper eye protection 3, 13.
Fire Hazards	Ignition of combustible materials	Remove or protect combustible materials from the welding area 5, 12, 17. Use fire-resistant screens or shields 4, 17. Have fire extinguishing equipment readily available and maintain a fire watch 5, 12.
Exposure to Harmful Fumes and Gases	Respiratory irritation, sensitization, or poisoning	Use adequate ventilation, such as local exhaust hoods or mechanical ventilation 8, 11, 20. Use respiratory protection, such as air-purifying respirators or air-supplied respirators, when ventilation is insufficient 8, 11.
Electric Shock	Electrocution or serious injury	Ensure welding equipment is properly grounded and maintained [6]. Avoid welding in wet conditions [6]. Use insulated electrode holders and wear dry gloves 2, 4.
Confined Spaces	Asphyxiation, toxic fumes, fire, or explosion	Ensure adequate ventilation before entering the confined space 2, 9, 11. Test the atmosphere for oxygen levels and hazardous gases [4]. Have a standby person outside the confined space with rescue equipment 2, 9.
Noise	Hearing damage	Wear hearing protection, such as earplugs or earmuffs, when noise levels are high [7].

5. Personal Protective Equipment (PPE)

It is essential to use the proper PPE to protect against the hazards associated with welding operations 4, 17.

• Welding Helmet: Protects the face and eyes from arc radiation, sparks, and flying debris. Ensure the helmet has the correct filter lens shade for the welding task 3, 13.
• Safety Glasses/Goggles: Provides additional eye protection under the welding helmet or when performing tasks other than active welding 3, 13.
• Gloves: Leather gauntlet gloves with arm protection protect hands and arms from burns and sparks 4, 17.
• Flame-Resistant Clothing: Protects the body from burns and sparks. Woolen clothing is preferable to cotton, but if cotton is used, it should be chemically treated to reduce combustibility [8].
• Apron/Leggings: Leather or flame-resistant aprons and leggings provide additional protection against sparks and molten metal, especially during heavy work [8].
• Ear Protection: Earplugs or earmuffs protect against high noise levels [7].
• Respirator: Protects against harmful fumes and gases when adequate ventilation is not available 8, 11.

Inspect all PPE before each use for damage or wear. Replace damaged PPE immediately. Clean and maintain PPE according to the manufacturer's instructions 4, 17.

6. Equipment and Tools

It is essential to use the proper equipment and tools for welding operations and to ensure they are in good working condition 6, 14.

• Welding Machine: Provides the electrical current for arc welding. Ensure the machine is properly grounded and set to the correct voltage and amperage [6].
• Electrode Holder: Holds the welding electrode. Ensure it is properly insulated and in good condition 2, 5.
• Welding Cables: Carry the electrical current from the welding machine to the electrode holder and work clamp. Inspect cables for damage or wear before each use 3, 13.
• Work Clamp: Connects the welding machine to the workpiece. Ensure it provides a good electrical connection [6].
• Grinder: Used for preparing the workpiece and removing weld spatter. Wear appropriate eye and face protection when using a grinder 3, 13.
• Chipping Hammer: Used for removing slag from welds. Wear appropriate eye protection when using a chipping hammer 3, 13.
• Ventilation Equipment: Local exhaust hoods or fans to remove fumes and gases from the welding area 8, 11, 20.

Inspect all equipment and tools before each use for damage or wear. Remove any defective equipment from service. Maintain equipment according to the manufacturer's instructions [4].

7. Pre-Job Requirements

7.1 Training and Competency

Workers must be properly trained and qualified to operate welding equipment 6, 14. Required training may include:

• Welding safety training
• Equipment-specific training
• Hazard communication training
• Confined space entry training (if applicable)

7.2 Pre-Job Briefing

A pre-job briefing must be conducted before starting any welding operation. The briefing should cover:

• The scope of the work
• Potential hazards
• Control measures
• Emergency procedures
• PPE requirements
• Equipment inspection

7.3 Work Area Preparation

• Remove all combustible materials from the welding area, or protect them with fire-resistant covers 5, 12, 17.
• Ensure adequate ventilation is available 8, 11, 20.
• Set up fire-resistant screens or shields to protect other workers from arc radiation and sparks 4, 17.
• Inspect the welding equipment and ensure it is in good working condition [4].
• Ensure the work area is clean and free of slip, trip, and fall hazards [9].
• For work in confined spaces, follow confined space entry procedures, including atmospheric testing and standby personnel 2, 9, 11.

8. Safe Work Procedure Steps

Step 1: Equipment Inspection and Setup

Inspect the welding machine, cables, electrode holder, and work clamp for any damage or defects [4].

• Sub-step 1.1: Ensure the welding machine is properly grounded [6].
• Sub-step 1.2: Connect the work clamp to the workpiece [6].
• Sub-step 1.3: Insert the correct electrode into the electrode holder 2, 5.

Safety considerations for this step: Damaged equipment can cause electric shock or fire. Ensure all equipment is in good working condition before use 11, 19.

Step 2: Welding Operation

Position yourself comfortably and safely before starting the welding operation.

• Sub-step 2.1: Put on your welding helmet and other PPE 3, 4, 13, 17.
• Sub-step 2.2: Strike an arc and begin welding, maintaining a consistent arc length and travel speed 3, 13.
• Sub-step 2.3: Monitor the welding process and adjust settings as needed [6].

Safety considerations for this step: Maintain a safe distance from the arc to avoid burns and eye injuries 4, 9. Ensure adequate ventilation to avoid exposure to harmful fumes and gases 8, 11, 20.

Step 3: Post-Welding Procedures

Allow the workpiece to cool before handling it.

• Sub-step 3.1: Remove slag from the weld using a chipping hammer and wire brush 3, 13.
• Sub-step 3.2: Inspect the weld for any defects [5].
• Sub-step 3.3: Clean the work area and store equipment properly [9].

Safety considerations for this step: Hot metal can cause burns. Use tongs or pliers to handle hot workpieces. Mark the hot metal or provide some other means of warning other workers 2, 18.

9. Precautions and Safety Measures

• Fire Prevention: Remove or protect combustible materials from the welding area 5, 12, 17. Keep fire extinguishing equipment readily available and maintain a fire watch for at least 30 minutes after welding is complete 5, 12.
• Ventilation: Ensure adequate ventilation to remove harmful fumes and gases 8, 11, 20. Use local exhaust hoods or fans when welding in confined spaces or areas with poor ventilation 2, 9, 11.
• Eye Protection: Always wear a welding helmet with the correct filter lens shade when arc welding or cutting 3, 13. Wear safety glasses or goggles for additional eye protection 3, 13.
• Electrical Safety: Ensure welding equipment is properly grounded and maintained [6]. Avoid welding in wet conditions. Use insulated electrode holders and wear dry gloves 2, 4.
• Confined Space Entry: Follow confined space entry procedures, including atmospheric testing, ventilation, and standby personnel 2, 9, 11.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, follow these general procedures:

• Stop work immediately and assess the situation.
• Alert others in the area.
• Activate the emergency alarm system.
• Evacuate the area if necessary.
• Provide first aid if needed.
• Contact emergency services.

10.2 Specific Emergency Scenarios

• Fire: Use a fire extinguisher to put out the fire. If the fire is too large to extinguish, evacuate the area and call emergency services 5, 12.
• Electric Shock: Turn off the power to the welding equipment. If the person is still in contact with the electrical source, use a non-conductive object to remove them. Provide first aid and call emergency services [6].
• Exposure to Harmful Fumes: Move the affected person to fresh air. Provide oxygen if needed. Seek medical attention 8, 11, 20.

10.3 Emergency Contact Information

• Emergency Services: 911
• [Company Safety Officer]: [PHONE NUMBER]
• [First Aid Responder]: [PHONE NUMBER]

11. Incident Reporting and Investigation

All incidents, near-misses, and hazards must be reported to the supervisor immediately [5].

An investigation will be conducted to determine the root cause of the incident and to implement corrective actions to prevent recurrence [5].

12. References and Related Documents

• CSA standard CSA W117.2, 'Safety in Welding, Cutting, and Allied Processes' 14, 17.
• ANSI Z 87.1-1968--American National Standard Practice for Occupational and Educational Eye and Face Protection [8].
• Requirements for Electric Arc-Welding Apparatus, NEMA EW-1-1962, National Electrical Manufacturers Association [10].
• Safety Standard for Transformer-Type Arc-Welding Machines, ANSI C33.2-1956, Underwriters' Laboratories [10].

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Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]

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